Method and apparatus for assembling a double-walled container

ABSTRACT

An assembly system for wrapping an outer wrapper to an inner sleeve to form an outer wall of a double-wall container can include a moveable suction arm. The moveable suction arm can be configured to couple to a suction source and can have a portion defining a suction surface. A plurality of suction openings can be provided within the suction surface and fluidly coupled to the suction source. A sealing edge can circumscribe at least a portion of the suction surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent applicationSer. No. 15/460,313, filed Mar. 16, 2017, which is incorporated hereinby reference in its entirety.

BACKGROUND

Insulated containers, such as cups, can be used to store hot or coldbeverages or food while providing a consumer holding the container withsome protection from the temperature of the items stored in thecontainer. Various methods, containers, and auxiliary devices forproviding insulation to a container to keep the contents of thecontainer warm/cold and to lessen the effects of the transfer of heat toor from a user's hand are known in the art. One such method includesproviding a double-walled container having an inner cup and an outerwrapper. The inner cup and the outer wrapper can both be formed, forexample, of paper and can additionally be provided with a coating on oneor more surfaces. The outer wrapper and the inner cup can be maintainedin a spaced condition to one another, defining an air gap therebetween.Forming such a cup to maintain the spaced condition can increase thecomplexity and cost of the manufacturing process.

BRIEF SUMMARY

In one aspect, illustrative embodiments in accordance with the presentdisclosure relate to an assembly system for wrapping an outer wrapper toan inner sleeve to form an outer wall of a double-wall container, theassembly system comprising a moveable suction arm configured to coupleto a suction source and having a portion defining a suction surface, aplurality of suction openings provided within the suction surface andfluidly coupled to the suction source, and a flexible sealing edgecircumscribing at least a portion of the suction surface and having anunflexed position in contact with a portion of the outer wrapper in anunwrapped condition and a flexed position in contact with the outerwrapper in a wrapped condition.

In another aspect, illustrative embodiments in accordance with thepresent disclosure relate to a wrapping station for wrapping an outerwrapper about an inner cup to form a double-wall container, the wrappingstation comprising a moveable suction arm configured to couple to asuction source and having a portion defining a suction surface forholding the outer wrapper against the suction surface by suction fromthe suction source, a plurality of suction openings provided within thesuction surface and fluidly coupled to the suction source, and aflexible sealing edge circumscribing at least a portion of the suctionsurface and having an unflexed position in contact with a portion of theouter wrapper in an unwrapped condition and a flexed position in contactwith the outer wrapper in a wrapped condition, wherein the flexiblesealing edge moves from the unflexed position to the flexed position asthe outer wrapper is wrapped upwardly about the inner cup.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a front elevation view of a double-walled cup having an innercup and an outer wrapper according to an embodiment of the disclosure.

FIG. 2 is a cross-sectional view of the cup of FIG. 1.

FIG. 3 is a schematic bottom view of the inner cup and the outer wrapperof FIG. 2 in a start position according to an embodiment of thedisclosure.

FIG. 4 is a schematic bottom view of the inner cup and the outer wrapperof FIG. 3 in a contacting position according to an embodiment of thedisclosure.

FIG. 5 is a schematic bottom view of the inner cup and the outer wrapperof FIG. 4 in a fully wrapped position according to an embodiment of thedisclosure.

FIG. 6 is a schematic bottom view of the inner cup and the outer wrapperof FIG. 5 in the fully wrapped position with a press arm fully extendedaccording to an embodiment of the disclosure.

FIG. 7 is a schematic view of an assembly system for wrapping the outerwrapper about the inner cup to form the double-walled container of FIG.2 according to an embodiment of the disclosure.

FIG. 8 is a perspective view of a suction apparatus that can be used tomake the cup of FIG. 2 according to an embodiment of the disclosure.

FIG. 9 is a side cross-sectional view of the suction apparatus of FIG.8.

FIG. 10 is a perspective view of a suction apparatus that can be used tomake the cup of FIG. 2 according to another embodiment of thedisclosure.

FIG. 11 is a cross-sectional view of the suction apparatus of FIG. 10 inan unflexed position.

FIG. 12 is a cross-sectional view of the suction apparatus of FIG. 10 ina flexed position.

FIG. 13 is a cross-sectional view of the suction apparatus of FIG. 10according to another embodiment of the disclosure.

The various features in this application illustrate examples ofdouble-walled cups and portions thereof according to this disclosure.The figures referred to above are not necessarily drawn to scale, shouldbe understood to provide a representation of particular embodiments ofthe disclosure, and are merely conceptual in nature and illustrative ofthe principles involved. Some features of the double-walled cupsdepicted in the drawings may have been enlarged or distorted relative toothers to facilitate explanation and understanding.

DETAILED DESCRIPTION

Cups described herein are susceptible of embodiments in many differentforms. Thus, the embodiments shown in the drawings and described indetail below exemplify the principles of the disclosure and are notintended to limit the broad aspects of the disclosure. Particularly, adouble-walled container is generally described and shown herein as a cupfor containing hot liquid, such as coffee, tea, etc. However, it shouldbe understood that the present disclosure may take the form of manydifferent types of vessels or containers for holding heated contents,including but not limited to liquids and non-liquids such as beverages,soups, stews, chili, noodles, etc. Additionally, a person skilled in theart would readily recognize that the double-walled vessel or containerof the present disclosure may also be used to insulate cold contents,such as an ice-cold beverage, in addition to hot beverages.

Referring now in detail to the figures, and initially to FIGS. 1 and 2,there is shown an embodiment of a double walled container 100. Thecontainer 100 defines an interior volume or container cavity orreceptacle 105 (see FIG. 2) for holding beverages or other items placedtherein. In addition, the container 100 provides insulation properties.

Referring to FIG. 2, according to aspects of the disclosure, thecontainer 100 includes an inner cup 200, an outer wrapper 300 (sometimesreferred to as a sleeve), and a base element 400. The outer wrapper 300is positioned around the inner cup 200 and held in spaced relationshiptherefrom to define a spaced condition between the inner cup 200 and theouter wrapper 300 that defines a cavity 130, which provide an insulationzone between the inner cup 200 and the outer wrapper 300.

The inner cup 200 defines an inner wall 210, which can be a sleeve, suchthat the sleeve together with the base element 400 or bottom form theinner cup 200. The outer wrapper 300 defines an outer wall 310. Theinner cup 200 terminates in a rim 112 at its upper end, which can beprovided as a rolled or at least partially rolled rim 112. The rim 112of the inner cup 200 forms the rim 112 for the container 100. While theouter wrapper 300 is illustrated herein as extending behind andcontacting the rim 112, it will be understood that the outer wrapper 300can be provided such that is does not extend behind or contact the rim112. The inner wall 210 and outer wall 310 collectively form adouble-walled sidewall 110 for the container 100, which is illustratedas having a frustoconical shape. However, other shapes are contemplated.The base element 400 functions as the bottom of the receptacle 105 inthe double-wall configuration. The base element 400 is generallypositioned in the lower portion of the container 100 and extendsinwardly from the inner wall 210 such that the lower end of thecontainer 100 (and of receptacle 105) is closed. The base element 400can be recessed a vertical distance above a lowermost bottom edge 108 ofthe container sidewall 110.

While the container 100 and its structural features, including but notlimited to the inner wall 210, outer wall 310, rim 112, and base element400, are illustrated schematically herein, it will be understood thatthese features are not limited to a plain schematic appearance asillustrated herein, but can have additional structural features that arenot disclosed here. For example, the lower portion of the base element400, the inner wall 210, and/or the outer wall 310 can be provided withstructural features that engage one another in ways not detailed in theillustrations herein, including but not limited to the incorporation ofstacking features or spacing features. By further example, while theinner wall 210 and the outer wall 310 are illustrated herein asgenerally smooth-walled elements, it will be understood that the innerwall 210 and the outer wall 310 can include a variety of structurallyraised or indented features, such as ribs, cusps, ridges, meshes,protuberances, bumps, channels, dimples, rings, etc. Further, any of thesidewall 110 surfaces can include one or more seams and/or overlappedportions due to manufacturing processes.

In an exemplary embodiment, the inner wall 210, the outer wall 310, andthe base element 400 can be formed of a paper product. Further, the baseelement 400, the inner wall 210, and/or the outer wall 310 can furtherinclude any suitable surface texture or coating. However, it will beunderstood that the inner wall 210, the outer wall 310, and the baseelement 400 are not limited to being formed of a paper product. By wayof non-limiting example, it is contemplated that the inner wall 210 andthe base element 400 can be formed of a plastic or a foam, while theouter wall 310 can be formed of a paper product. It is possible for theinner wall 210, outer wall 310, and base element 400 be made from paper,foam, or foam coated paper, in any possible combination.

A spacer, illustrated in this embodiment as an adhesive 120, can bepresent within the cavity 130, and contacting both the inner wall 210and the outer wall 310. While the spacer has been illustrated herein asan adhesive 120, it will be understood that the spacer can comprise anysuitable spacing means such as, by way of non-limiting example, at leastone of an adhesive, a bead, a strip of foam or other material, such asplastic, or a structural member protruding into the cavity 130 from atleast one of the inner cup 200 or the outer wrapper 300. The adhesive120 can further function to maintain the spaced condition of the innerwall 210 and the outer wall 310. The adhesive 120 can be applied in anysuitable manner, including but not limited to, discrete applications inthe form of dots, circles, or lines of adhesive 120, or a continuousapplication, such as a spiral, in any suitable pattern such that theadhesive 120 as applied has a height or width that maintains the innerwall 210 and the outer wall 310 in the spaced condition with oneanother, the adhesive 120 not being flat or substantially flat.

Turning now to FIGS. 3-6, a method of wrapping the outer wrapper 300about the inner cup 200 to form the double-walled container 100 isillustrated. The sequence of steps depicted for this method is forillustrative purposes only, and is not meant to limit the method in anyway as it is understood that the steps can proceed in a differentlogical order or additional or intervening steps can be included withoutdetracting from the method of the disclosure.

FIG. 3 shows a bottom view of the inner cup 200 and the outer wrapper300 in a start position. The method can begin with the inner cup 200having been provided with the adhesive 120. The applying of the adhesive120 can comprise multiple discrete applications of adhesive 120 atmultiple locations on the inner cup 200. By way of non-limiting example,the multiple discrete applications of adhesive 120 can include dots,lines, or rings. The inner cup 200 can be held by, by way ofnon-limiting example, suction on a mandrel 550 (FIG. 7) that can bepositioned within the receptacle 105 of the inner cup 200. The adhesive120 is provided about the circumference of the inner cup 200. A pressarm 570 is positioned above the inner cup 200 and spaced away from theinner cup 200.

The outer wrapper 300 overlies and is held by suction on a suction arm500. In the start position, the outer wrapper 300 is flat and held outof contact with the adhesive 120 on the inner cup 200, but is verticallyaligned with the inner cup 200 and is ready to be moved upward towardthe inner cup 200 in the direction shown by the arrows 502. When theouter wrapper 300 in the pre-wrapped condition is placed such that itoverlies the suction arm 500, suction is provided through the suctionarm 500 in order to hold the outer wrapper 300 in place against thesuction arm 500. In an exemplary embodiment, the suction arm 500contacts the outer wrapper 300 at a location between opposing ends 315,320 of the outer wrapper 300, generally at a point centrally locatedbetween the opposing ends 315, 320 of the outer wrapper 300. The outerwrapper 300 can be provided with an adhesive 125 applied on at least oneor the other of the opposing ends 315, 320. In an exemplary embodiment,the adhesive 125 is applied to the opposing end 315, 320 that willoverlie the other of the opposing ends 315, 320 when the outer wrapper300 is wrapped around the inner cup 200. While the adhesive 125 isillustrated herein as being provided on the opposing end 320, it will beunderstood that the adhesive 125 can be provided on the other opposingend 315 in the case that the opposing end 315 were wrapped on theoutside of the opposing end 320. Wrapping arms 560 are positioned belowthe outer wrapper 300 and generally adjacent to the opposing ends 315,320. The wrapping arms 560 in the start position are lowered and not incontact with the outer wrapper 300.

FIG. 4 shows a bottom view of the inner cup 200 and the outer wrapper300 in a contacting position. In the contacting position, at least oneor both of the inner cup 200 and the outer wrapper 300 is moved towardthe other of the inner cup 200 and the outer wrapper 300 such that theouter wrapper 300 is brought into physical contact with the adhesive 120that has been applied to the inner cup 200. In an exemplary embodiment,while the outer wrapper 300 contacts the adhesive 120 on the inner cup200, the inner cup 200 and the outer wrapper 300 are held in a spacedcondition from one another such that the adhesive 120 is notsubstantially compressed by the contact between the inner cup 200 andthe outer wrapper 300, maintaining the width of the cavity 130. In thecontacting position, the wrapping arms 560 can begin to rotate inwardlytowards the outer wrapper 300 in the direction indicated by the arrows504. As the wrapping arms 560 rotate further inwardly and upwardly, in acurved arc of movement, towards the outer wrapper 300, the wrapping arms560 urge the outer wrapper 300 about the inner cup 200, forcing theopposing ends 315, 320 of the outer wrapper 300 upwardly around theinner cup 200 in a circumferential manner, such that the outer wrapper300 is wrapped about the inner cup 200 while still maintaining the outerwrapper 300 in the spaced condition. The outer wrapper 300 is wrappedabout the inner cup 200 until the opposing ends 315, 320 overlap oneanother to define an overlapped portion 580 (see FIG. 5).

FIG. 5 shows a bottom view of the inner cup 200 and the outer wrapper300 in a fully wrapped position. In the fully wrapped position, whilethe outer wrapper 300 and the inner cup 200 are still maintained in thespaced condition from one another, the outer wrapper 300 has been forcedcompletely about the inner cup 200 by the wrapping arms 560 such thatthe opposing ends 315, 320 have been wrapped about the inner cup 200completely to overlap one another and define the overlapped portion 580.The wrapping arms 560 are shaped and their movement controlled such thatthey maintain the cavity 130 about the circumference of the inner cup200. As illustrated herein, the adhesive 125 applied to the opposing end320 has come into contact with the other opposing end 315. The wrappingarms 560 have moved in the direction of the arrows 504 (FIG. 4) to theirupward extent in the fully wrapped position. Further, the press arm 570has begun to move downward toward the overlapped portion 580 of theouter wrapper 300.

FIG. 6 shows a bottom view of the inner cup 200 and the outer wrapper300 in a fully wrapped position with the press arm 570 fully extended.When the press arm 570 is fully extended, the press arm 570 contacts theoverlapped portion 580 and applies pressure to the overlapped portion580 such that the overlapped portion 580 is pressed toward the inner cup200. The pressing of the overlapped portion 580 toward the inner cup 200compresses the adhesive 125 at least partially, but the pressing can beinsufficient for the overlapped portion 580 to physically contact theinner cup 200. However, while the press arm 570 is illustrated herein asnot pressing the overlapped portion 580 toward the inner cup 200 withsufficient force to cause the overlapped portion 580 to physicallycontact the inner cup 200, it will be understood that the press arm 570can press the overlapped portion 580 toward the inner cup 200 with anysuitable amount of pressure, up to and including that the pressure issufficient to cause the overlapped portion 580 to be pressed completelyagainst the inner cup 200. It is also contemplated that the press arm570 can press the overlapped portion 580 such that it does not movetoward the inner cup 200, or that the overlapped portion 580 can becompressed any suitable distance therebetween.

The press arm 570 can be held against the overlapped portion 580 for anysuitable length of time such that the adhesive 125 that was applied toat least one of the opposing ends 315, 320 of the outer wrapper 300 cansufficiently bond to the other of the opposing ends 315, 320. When asuitable length of time has passed for the overlapped portion 580 to besufficiently adhered together, the press arm 570 and the wrapping arms560 are withdrawn from contact with the outer wrapper 300. When thewrapping has been completed, the application of suction to the outerwrapper 300 by the suction arm 500 is ceased so that the formeddouble-walled container 100 can then be indexed away from the wrappingstation for packaging or for further processing, such as the addition ofstructural or stacking features, or for printing on the outer wrapper300.

FIG. 7 illustrates a schematic view of an assembly system 600 forwrapping the outer wrapper 300 about the inner cup 200 to form thedouble-walled container 100. First, a web 605 carrying a plurality ofouter wrappers 300 enters the assembly system 600. The outer wrapper 300are illustrated herein as having already been provided with the adhesive125. It will also be understood that the outer wrappers 300 on the web605 might not yet include the adhesive 125, and that the adhesive 125will rather be applied to the outer wrapper 300 at a later point duringthe wrapping process.

A first rotating spindle 610 has a plurality of extending arms 615disposed radially about the first rotating spindle 610. At the end ofeach of the extending arms 615 is a suction arm 500. As a suction arm500 is brought into alignment with an outer wrapper 300, the outerwrapper 300 is transferred to the suction arm 500 from the web 605 andis held in place on the suction arm 500 by suction force being appliedby the suction arm 500. The suction arm 500 carrying the outer wrapper300 is then rotated about the rotating spindle 610 until it is broughtinto alignment with the wrapping station 640. The suction arm 500 isalso movable up/down relative to the outer wrapper 300. The wrappingstation 640 includes the wrapping arms 560 and the press arm 570, withthe wrapping arms 560 and the press arm 570 occupying the start positionwhen the outer wrapper 300 is indexed into place in the wrapping station640.

Before wrapping of the outer wrapper 300 can proceed, an inner cup 200is provided to the wrapping station 640. A second rotating spindle 625is provided that can carry the inner cups 200. The second rotatingspindle 625 has a plurality of extending arms 620 disposed radiallyabout the second rotating spindle 625. At the end of each of theextending arms 620 is a mandrel 550. The mandrel 550 can be providedwith air channels (not shown) that allow the mandrel 550 to providesuction force to hold an inner cup 200 about the mandrel 550. A supplytube 645 can contain a stack 650 of inner cups 200. When a mandrel 550lines up with the open end of the supply tube 645 and applies suction,an inner cup 200 can be sucked out or blown out of the supply tube 645and onto the mandrel 550, then held on the mandrel 550 by suction. Themandrel 550 is then rotated by the second rotating spindle 625 to indexan inner cup 200 into position within the wrapping station 640. At thewrapping station 640, the outer wrapper 300 is wrapped about the innercup 200 to form the double-walled container 100 as described in FIGS.3-6.

When formation of the double-walled container 100 at the wrappingstation 640 has been completed, the second rotating spindle 625 indexesthe mandrel 550 carrying the double-walled container 100 out of thewrapping station. The double-walled container 100 can then be broughtinto alignment with a stacking tube 630. The stacking tube 630 can beprovided to contain a stack 635 of double-walled containers 100. Whenthe mandrel 550 carrying a double-walled container 100 lines up with theopen end of the stacking tube 630, the application of suction to thedouble-walled container 100 by the mandrel 550 is ceased. Thedouble-walled container can then be taken up into the stacking tube 630,either by the application of suction from the stacking tube 630, bybeing blown off the mandrel 550 by positive air pressure applied by themandrel 550, or a combination thereof.

While the outer wrapper 300 and the inner cup 200 have been describedherein as being held in the spaced condition to one another by theadhesive 120 that is applied to the inner cup 200 prior to the wrappingof the outer wrapper 300 about the inner cup 200, it will also beunderstood that a non-adhesive spacer could be used instead of or inaddition to the adhesive 120 applied to the inner cup 200. The spacerwill maintain the outer wrapper 300 and the inner cup 200 in the spacedcondition to one another regardless of whether or not the spacer hasadhesive properties. The spacer can comprise, by way of non-limitingexample, at least one of an adhesive, a bead, a strip of foam or othermaterial, or a structural member protruding into the cavity 130 from atleast one of the inner cup 200 or the outer wrapper 300. A spacer withno adhesive properties would still result in a double-walled container100 with the intended function and properties as the outer wrapper 300and the inner cup 200 would be maintained in the spaced condition fromone another, and the outer wrapper 300 would still be held in a fullywrapped condition about the inner cup 200 by way of the adhesive that isprovided to at least one of the opposing ends 315, 320 of the outerwrapper 300 prior to wrapping of the outer wrapper 300 about the innercup 200 to form the overlapped portion 580.

The presence of the spacer allows the outer wrapper 300 and the innercup 200 to be maintained in the spaced condition from one another, evenas the outer wrapper 300 is mechanically wrapped about the inner cup200. In methods of forming a double-walled container in which the outerwrapper is pre-formed into a sleeve and then slid over the inner cup,maintaining the spaced condition of the inner cup and the outer wrapperdoes not pose the same manufacturing challenge as the two components arealready sized and formed to fit in the spaced condition from oneanother. However, such a method of assembly can result in smearing ofthe adhesive between the inner cup and the outer wrapper, compromisingthe cavity and potentially resulting in deformations that could beunpleasant to the consumer. The wrapping method of the disclosure solvesthe issue of providing a method for forming a double-walled container inwhich the outer wrapper can be wrapped about the inner cup, rather thanslid over the inner cup, to maintain the integrity of the adhesivepattern, as well as ensuring that the inner cup and the outer wrapperare maintained in the spaced condition through the assembly process toensure the cavity is properly defined at all points.

Referring now to FIG. 8, a suction arm 500 that can be used in theassembly system 600 to make the double-walled container 100 according toan embodiment of the disclosure is illustrated. The suction arm 500 caninclude a base portion 505 that is generally stationary in relation tothe extending arm 615 and can be provided in a substantially horizontalorientation. The base portion 505 can be operably coupled to a suctionsource (not shown) via a pressure opening 510. The suction arm 500 canfurther include an angled portion 515. The angled portion 515 ismechanically coupled to the base portion 505 and can be provided at anangle relative to the base portion 505. It is further contemplated thatthe angled portion 515 can be adjustable relative to the base portion505 such that the angle of the angled portion 515 can be adjusted toaccommodate the pitch of the container 100 to be assembled. In anexemplary embodiment, the angle of the angled portion 515 will beadjusted such that it corresponds to the angle of the inner wall 210 ofthe inner cup 200. At least one suction nozzle 520 can be providedextending from an upper surface 525 of the angled portion 515. Thesuction nozzles 520 can selectively provide suction or negative pressureto hold in place a blank or outer wrapper 300 that is applied to theangled portion 515.

Referring now to FIG. 9, a side cross-sectional view of the suction arm500 of FIG. 8 is shown. In this view, it can be better seen that thebase portion 505 of the suction arm 500 can define a suction channel530. The suction channel 530 can include suction branches 535. In anexemplary embodiment, the number of suction branches 535 is equal to thenumber of suction nozzles 520 that are provided on the angled portion515. The suction branches 535 extend upwardly into the suction nozzles520 to provide a suction force to the suction nozzles 520.

Referring now to FIG. 10, a suction arm 700 that can be used in theassembly system 600 to make the double-walled container 100 according toanother embodiment of the disclosure is illustrated. The suction arm 700is similar to the suction arm 500 in that the suction arm 700 caninclude a base portion 705 that is generally stationary in relation tothe extending arm 615 and can be provided in a substantially horizontalorientation. However, it will be understood that a substantiallyhorizontal orientation is not limiting, and that the base portion 705can be provided at any suitable angle relative to the horizontal. Thebase portion 705 can be operably coupled to a suction source (not shown)via a suction outlet 710. The suction arm 700 can also be moveable andconfigured to couple to the suction source.

The suction arm 700 can further include an angled portion 715. Theangled portion 715 is mechanically coupled to the base portion 705 andcan be selectively provided at an angle relative to the base portion705. It is further contemplated that the angled portion 715 can beadjustable in angle relative to the base portion 705 such that the angleof the angled portion 715 relative to the base portion 705 can beadjusted to accommodate the pitch of the container 100 to be assembled.In an exemplary embodiment, the angle of the angled portion 715 can beadjusted such that it corresponds to the angle of the inner wall 210 ofthe inner cup 200.

While the angled portion 515 was provided with suction nozzles 520extending from the upper surface 525 of the angled portion 515, it iscontemplated that the angled portion 715 can define a suction surface725. The suction surface 725 can be provided with a plurality of suctionopenings 720 that are fluidly coupled to the suction source. The suctionopenings 720 can be provided within the suction surface 725 in anysuitable pattern. In an exemplary embodiment, the suction openings 720can be arranged in rows on the suction surface 725 and can bedistributed evenly throughout the suction surface 725. However, it willbe understood that the arrangement of the suction openings 720 on thesuction surface 725 is not limiting.

The suction surface 725 can further comprise a sealing edge 740 thatextends about the periphery of the suction surface 725 and circumscribesat least a portion of the suction surface 725. In an exemplaryembodiment, the sealing edge 740 is formed from a flexible material suchthat the sealing edge 740 can conform to the outer wrapper 300 as theouter wrapper 300 is wrapped upwardly around the inner cup 200. Thesealing edge 740 can form a continuous perimeter about the periphery ofthe suction surface 725 such that an airtight suction seal can be formedbetween the outer wrapper 300 and the sealing edge 740. In an exemplaryembodiment, the sealing edge 740 is substantially flush with the suctionsurface 725, such that the sealing edge 740 minimally increases theheight of the suction surface 725.

FIG. 11 illustrates a cross-sectional view of the angled portion 715 inwhich the sealing edge 740 is in an unflexed position. The suctionsurface 725 can be provided as a curved suction surface 725, such thatthe left and right peripheral edges where the sealing edge 740 ispositioned are higher than the center of the suction surface 725. Thedegree of curvature of the suction surface 725 can be any suitablecurvature. In an exemplary embodiment, the degree of curvature of thesuction surface 725 will be the same as the desired degree of curvatureof the outer wrapper 300 about the inner cup 200 such that the inner cup200 and outer wrapper 300 can rest complementary to the suction surface725. It will be understood that the degree of curvature of the suctionsurface 725 can also be provided as flatter than or shallower than thedesired degree of curvature of the outer wrapper 300 about the inner cup200. Further, the degree of curvature of the suction surface 725 can berelated to the radius of the inner cup 200 or the double-walledcontainer 100 being wrapped. Each of the suction openings 720 can befluidly coupled to the suction outlet 710 via suction channels 745defined by the angled portion 715.

The sealing edge 740 can be thought of as comprising a sealing body 750and a sealing flange 755. The sealing body 750 can extend downwardlyrelative to the suction surface 725 for attachment to the angled portion715, while the sealing flange 755 extends outwardly from the sealingbody 750, away from the center of the suction surface 725. In anexemplary embodiment, the sealing flange 755 can narrow or taper awayfrom the center of the suction surface 725. It will be understood thatthe sealing body 750 may be substantially stationary while the sealingflange 755 can flex upwardly and downwardly relative to the suctionsurface 725.

FIG. 12 illustrates a cross-sectional view of the angled portion 715 inwhich the sealing edge 740 is in a flexed position. In the flexedposition, the sealing flange 755 flexes upwardly away from the suctionsurface 725. This occurs as the outer wrapper 300 is wrapped upwardlyaround the inner cup 200 due to suction coupling between the sealingflange 755 and the outer wrapper 300.

FIG. 13 illustrates a cross-sectional view of the angled portion 715with the sealing edge 740 in the unflexed position according to anotherembodiment of the invention. In this embodiment, the structure of theangled portion 715 and the sealing edge 740 is the same as that shown inFIG. 11, except that the suction surface 725 and the sealing flange 755are flat. Rather than having a curvature as in the embodiment of FIG.11, the suction surface 725 and the sealing flange 755 are substantiallyhorizontal and without curvature in the unflexed position.

Turning now to the operation of the suction surface 725, when the outerwrapper 300 is to be wrapped upwardly around the inner cup 200, theouter wrapper 300 is indexed into place onto the angled portion 715.When the outer wrapper 300 is in place on the angled portion 715, theouter wrapper 300 contacts the sealing flange 755 about the entireperimeter of the sealing flange 755. Suction or negative pressure isapplied by the suction source via the suction outlet 710 and the suctionchannels 745 to the suction openings 720. The force of the suction fromthe suction openings 720 against the outer wrapper 300 causes a suctionseal to be formed between the outer wrapper 300 and the sealing flange755. In an exemplary embodiment, the suction seal can be an airtightseal, though it will be understood that the suction seal need not beperfectly airtight, so long as the suction is sufficient to hold theouter wrapper 300 in place as the outer wrapper 300 is wrapped upwardlyabout the inner cup 200. The suction and the seal between the outerwrapper 300 and the sealing flange 755 are maintained as wrapping of theouter wrapper 300 proceeds. As the outer wrapper 300 is wrapped upwardlyabout the inner cup 200, the airtight seal and the suction cause thesealing flange 755 to stay in contact with the outer wrapper 300 and tomove with the outer wrapper 300 from the unflexed position to the flexedposition, such that the sealing flange 755 moves from the unflexedposition to conform to the shape of the outer wrapper 300 as it iswrapped about the inner cup 200. The sealing flange 755 can maintain theflexed position against the outer wrapper 300 until the overlappedportion 580 has been adhered. Once the formation of the double-walledcontainer 100 at the wrapping station 640 has been completed, thesuction can cease and the double-walled container 100 is removed fromthe angled portion 715.

The embodiments of the disclosure described herein provide a method ofmaking a double-walled cup or container, which can be formed of paper,which can be used to address challenges associated with forming aninsulating cup by ensuring that the inner cup and the outer wrapper aremaintained in a spaced condition from one another for optimal insulativeperformance of the cavity. If the spacer or adhesive were not present orwere to become compressed, the width of the cavity between the inner cupand the outer wrapper would be decreased, which would negatively impactthe insulative performance of the double-walled cup. The methodsdescribed herein allow for the manufacture of a double-walled cup in away in which the spaced condition is maintained at a desired width withdecreased opportunity for the spacer or adhesive to become undesirablycompressed about the circumference of the cup. The provision of thesealing flange with its flexibility and ability to conform to the shapeof the double-walled cup or container allowed for a better seal that canbe maintained even as the outer wrapper is wrapped about the inner cup.By maintaining the suction and the airtight seal between the sealingflange and the outer wrapper throughout the wrapping step and until theoverlapped portion has been fully adhered, it can be ensured that theouter wrapper does not shift or move out of place on the angled surface.This allows for consistent positioning of the outer wrapper during thewrapping process, resulting in the formation of consistent and correctdouble-walled containers.

To the extent not already described, the different features andstructures of the various embodiments of the disclosure may be used incombination with each other as desired. That one feature may not beillustrated in all of the embodiments is not meant to be construed thatit cannot be, but is done for brevity of description. Thus, the variousfeatures of the different embodiments may be mixed and matched asdesired to form new embodiments, whether or not the new embodiments areexpressly described.

While the disclosure has been specifically described in connection withcertain specific embodiments thereof, it is to be understood that thisis by way of illustration and not of limitation. Reasonable variationand modification are possible within the scope of the forgoingdisclosure and drawings without departing from the spirit of thedisclosure which is defined in the appended claims.

What is claimed is:
 1. An assembly system for wrapping an outer wrapperto an inner sleeve to form an outer wall of a double-wall container, theassembly system comprising: a moveable suction arm configured to coupleto a suction source and having a portion defining a suction surface; aplurality of suction openings provided within the suction surface andfluidly coupled to the suction source; and a flexible sealing edgecircumscribing at least a portion of the suction surface and having anunflexed position in contact with a portion of the outer wrapper in anunwrapped condition and a flexed position in contact with the outerwrapper in a wrapped condition.
 2. The assembly system of claim 1wherein the moveable suction arm comprises an angled portion, the angledportion defining the suction surface.
 3. The assembly system of claim 2wherein the angled portion can be adjusted to accommodate a pitch of thedouble-wall container.
 4. The assembly system of claim 1 wherein theplurality of suction openings are distributed throughout the suctionsurface.
 5. The assembly system of claim 1 wherein the flexible sealingedge forms a continuous perimeter about the periphery of the suctionsurface.
 6. The assembly system of claim 5 wherein a suction seal isformed between the outer wrapper and the flexible sealing edge.
 7. Theassembly system of claim 6 wherein the suction seal is an airtightsuction seal.
 8. The assembly system of claim 1 wherein the flexiblesealing edge is substantially flush with the suction surface.
 9. Theassembly system of claim 1 wherein the suction surface has a degree ofcurvature that is the same as or flatter than a desired degree ofcurvature of the double-wall container.
 10. The assembly system of claim1 wherein the flexible sealing edge comprises a sealing body and asealing flange, the sealing flange defining the flexed position andunflexed position relative to the sealing body.
 11. A wrapping stationfor wrapping an outer wrapper about an inner cup to form a double-wallcontainer, the wrapping station comprising: a moveable suction armconfigured to couple to a suction source and having a portion defining asuction surface for holding the outer wrapper against the suctionsurface by suction from the suction source; a plurality of suctionopenings provided within the suction surface and fluidly coupled to thesuction source; and a flexible sealing edge circumscribing at least aportion of the suction surface and having an unflexed position incontact with a portion of the outer wrapper in an unwrapped conditionand a flexed position in contact with the outer wrapper in a wrappedcondition; wherein the flexible sealing edge moves from the unflexedposition to the flexed position as the outer wrapper is wrapped upwardlyabout the inner cup.
 12. The wrapping station of claim 11 wherein themoveable suction arm comprises an angled portion, the angled portiondefining the suction surface.
 13. The wrapping station of claim 12wherein an angle of the angled portion can be adjusted to correspond toan angle of the inner cup.
 14. The wrapping station of claim 11 whereinthe plurality of suction openings are distributed throughout the suctionsurface.
 15. The wrapping station of claim 11 wherein the flexiblesealing edge forms a continuous perimeter about the periphery of thesuction surface.
 16. The wrapping station of claim 15 wherein a suctionseal is formed between the outer wrapper and the flexible sealing edge.17. The wrapping station of claim 16 wherein the suction seal is anairtight suction seal.
 18. The wrapping station of claim 11 wherein theflexible sealing edge is substantially flush with the suction surface.19. The wrapping station of claim 11 wherein the suction surface has adegree of curvature that is the same as a desired degree of curvature ofthe double-wall container.
 20. The wrapping station of claim 11 whereinthe flexible sealing edge comprises a sealing body and a sealing flange,the sealing flange defining the flexed position and unflexed positionrelative to the sealing body.